6584

Access Diagnostics menu: Press DIAG → NCK → Memory → check TMP usage percentage. Compare current value against MD 20100 (NCK memory configuration). Document exact percentage to determine remaining free space.

Review NC program structure in editor: identify subroutine call depth using CALL statements. Reduce nesting levels and consolidate local variable declarations using G-code scope parameters. Replace recursive subroutines with iterative loop constructs where possible.

Verify subroutine parameter passing via MD 20050 (variable memory allocation) does not exceed 50% of available TMP.

Check machine data MD 22000 (local variable memory) and MD 22100 (work offset memory). If local variable range is set >2000 words, reduce allocation and reallocate freed memory back to global data space via MD 20000.

Clear residual TMP data: cycle power OFF for 30 seconds (full DRAM discharge), then restart NCK. Verify alarm clears on next program load. If alarm persists immediately, TMP partition is structurally full.

Verify installed DRAM: In Diagnostics → System Information → Hardware, confirm total memory (e.g., 512MB, 1GB, 2GB). Note memory model and revision for 840D vs. 840Di variants.

Check TMP partition configuration: Access Service menu → Machine → Memory Configuration (or via HMI System Parameters). Note current TMP size allocation (typically shown in MB or word count). Compare against MD 20100 documentation baseline for your control type.

Do not modify partition sizes without documenting original values. Changes require EEPROM programming and full NCK restart.

If TMP allocation is <15MB on 512MB system, or <30MB on 1GB+ system, request engineering to increase via BIOS configuration tool. Standard recommendation: allocate 25% of total DRAM to TMP partition. Changes persist only after power cycle with EEPROM write.

After partition resize, validate via Diagnostics → Memory → TMP Free Space. Run production part program and monitor TMP usage trend. Confirm no recurrence of alarm during full cycle.

Examine M-code sequences in program postamble: verify M06 (tool change) executes after each offset reset, and check that G10 offset commands include L20 (clear offset memory) parameter if required by your machine configuration.

Check machine data MD 26300-26399 (tool offset management): confirm automatic offset clearing is enabled (MD 26300 = 1). If disabled, add explicit CLEARO or G10 L20 commands before each new workpiece setup in NC program.

Manual offset clearing without proper syntax may leave orphaned data in TMP. Use only ISO G-code sequences validated in teach mode.

Review part program flow: insert G65/CALL between workpiece cycles with explicit cleanup subroutine (e.g., CLEARO D1 THRO D10, H1 THRO H10) to release temporary offset entries to free memory.

Monitor TMP fragmentation: run full production cycle and check Diagnostics → NCK → Memory Fragmentation ratio. If >40%, perform EEPROM garbage collection (Service → Maintenance → Memory Defragment). Retest alarm occurrence.